Title: SUSTAINABLE NYLON-BASED MULTI-SCALE COMPOSITE LAMINATES FOR NEXT-GENERATION EV BATTERY PACK PROTECTION

Authors: Rajesh Punia, Hemant Chouhan ,Mohit Garg, Kartikeya Kartikeya, Naresh Bhatnagar

DOI: https://doi.org/10.33599/GL.2026.INCOMAT.TP26-0022

Abstract: This study reports the development and performance evaluation of a sustainable multi-scale reinforced nylon laminate designed for electric vehicle (EV) battery pack protection. A recycled nylon (r-Nylon) matrix was modified with a synergistic combination of graphene nanoplatelets (GNP), carbon nanotubes (CNTs) and talc, compounded through co-rotating twin-screw extrusion. The resulting nanocomposite was processed into calendered sheets and consolidated with woven glass-fiber layers by compression molding to fabricate hybrid laminates. A commercial FR4 (flame-retardant) glass-fiber epoxy laminate was characterized and used as a benchmark for comparison. Mechanical testing showed that multi-scale reinforcement significantly enhanced the structural integrity and stiffness of the r-Nylon laminates. The hybrid system achieved an average ultimate tensile stress (UTS) of 191 MPa, representing a 35.7% increase over the FR4 benchmark value of 142 MPa while maintaining satisfactory toughness. FESEM morphological analysis confirmed uniform nanofiller dispersion and strong interfacial bonding. Flame-retardant testing indicated marked improvements in comparative fire performance, characterized by enhanced structural retention and the localized formation of a protective carbonaceous char layer. Furthermore, thermal analysis (TGA/DSC) demonstrated a delayed onset of thermal degradation and an increased residual mass (~7.0%) compared to the unmodified benchmark. The developed laminate exhibited competitive flame resistance and structural performance relative to FR4, establishing it as a lightweight, recyclable and thermally stable candidate for next-generation EV battery enclosures.

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Conference: INCOMAT 2026

Publication Date: 2026/03/13

SKU: INCOMAT.TP26-0022

Pages: 15

Price: $30.00